Energy monitoring guide
Machine running and idle time: straight from the energy meter.
A machine’s power draw tells you what it is doing. Above a set level it is running; just above zero it is idle; at zero it is stopped. Track that through the day against your shift timings and you see running hours, idle waste and unplanned stops without adding a single sensor.
Four states from one number
| State | What the meter sees | What it means |
|---|---|---|
| Stopped | Power near zero | Switched off. Planned if outside shift hours, unplanned if inside |
| Idle | Above zero, below the idle level you set | Powered on but not producing: hydraulics, heaters, spindles waiting |
| Running | Above the idle level | Producing |
| Overload | Above the rated level you set | Working harder than designed: check tooling, material, mechanics |
Two numbers per machine set it up: the idle level in kW and the rated level in kW. A few days of readings usually show both clearly.
Planned and unplanned stops
A stop at 2 a.m. on a one-shift plant is planned. A stop at 11 a.m. is not. Compare each stop with the shift timings and the timeline separates them on its own, so a morning meeting looks at unplanned stops instead of guessing.
Where idle energy hides
- Hydraulic power packs left running between jobs.
- Moulding and extrusion heaters held at temperature through breaks.
- Compressors loading and unloading to feed leaks overnight.
- Machines left on through lunch, shift changes and Sundays.
Idle hours multiplied by idle kW is energy paid for at full rate with nothing made. On a TOD tariff, idle load in peak hours costs even more. See TOD tariff.
Energy for each machine
Machine-wise energy needs a meter on that machine’s feeder. Fit meters on the largest machines first: compressors, furnaces, moulding machines, chillers. Smaller machines can share a panel meter. Enter daily production and each line shows energy per unit made. See sub-metering.
Running and idle tracking in KONDUKTOR® EMS
- A state timeline for each meter: running, idle, stopped planned, stopped unplanned, with overload marked.
- Idle and rated levels set per machine, and shift timings for up to 7 shifts.
- The kW chart shaded into running, idle and stopped bands.
- Alerts when a machine’s load crosses a limit you set, such as its rated level, and daily energy per meter.
Vibration and temperature sensors connect to the same RS-485 network, configured for your machines as part of your project. Automatic switch-off of idle machines through Modbus I/O cards is engineered for your plant the same way.
Common questions
Can an energy meter tell if a machine is idle?+
Yes. A machine draws a small, steady power when it is on but not producing, and much more when it is working. Set the idle and rated levels in kW for that machine, and its readings sort into running, idle, stopped and overload.
Is this machine health monitoring?+
Not on its own. Energy readings show running, idle, stopped and overload time, and the phase unbalance that stresses motors. Vibration and temperature sensors connect to the same network and are configured for your machines as part of your project.
Do we need a meter on every machine?+
No. Start with the largest loads: compressors, furnaces, moulding machines, chillers. Smaller machines can share a panel meter, which shows that panel’s running and idle time together.
See which machines run, and which just sit idle.
Book a live demo and see a state timeline on meters like yours.